Structural material and method for making the same



April 9, 1935. BRUNNER 1,997,293

STRUCTURAL MATERIAL AND' METHOD FOR MAKING THE SAME Filed June 8, 1934 I5 Sheets-Sheet l April 9 A. H. BRUNNER I 1,997,293

KING THE SAME STRUCTURAL MATERIAL ANb METHOD F0 R MA ' Filed June a, 1934 9 5 Sheets-Sheet 2 By I .il/orneys April 1935- A; H. BRUNNER 1,997,293

STRUCTURAL MATERIAL AND METHOD FOR MAKING THE SAME Filed June 8, 1934 5 Sheets-Sheet 3 .35 32*, a 35 F V32 Q7 .7 as

Inventor Patented Apr. 9, 1935 A r UNET T TA P T fiNfl ibF f T p 1,997,293 I r v STRUCTURAL MATERIAL AND METHOD FOR 'MAKINGTHE'SAME 1' I p I", AlbertH. Brunner, Los Angeles, Calif assignor to "Schumacher Wall Board Corporation, Los Angeles, Calif, a corporation of'Delaware v T 1 Applicationdnne s, 1934, sunrise-729,579

" 8Claims. (01.154 2) This invention relates to an improved. struc-' .-.A furtherobject isjtoadisclose and provide an tural material. of the typegenerally referredto as apparatus particularly adapted for the manuwall board, inwhich a core of suitable cementifacture ofimproved incased wallboard;

' tious composition is held between fibrous sheets, These and other :objects,uses, advantages and such as sheets of laminated: paper. The invenadaptations ofithis invention will become appar- 5 tion is particularly. directed toward a strucent to those skilledin'the art fromthe following. tural material which is incased within afibrous. detailed descriptionof the. finished product and covering so that both ofzthe major surfaces of the of the preferred method of operation and an ilboard as well-as the .longitudinal edges thereof lustrativeiform of. machine whereby the product are protected by thecoveringnj canbe made. 10

The invention. also relates to amethod of mak- 'In describing the invention, reference will be ing a wallb'oard of the character stated hereinhad to the appended drawings, in which: above, in a continuous, rapid and economical Fig.1 isa transversesection, p y d agra s manner; Moreover, the inventionisdirected tcmatic, through an improved form of incasedwall wardamachine. capable of being used with great board.,::;i effectivenessv in carrying out the method. and Fig. 2- is a'diagrammatic side elevatiompartly producing the product of this invention. a broken away, of a combination of elements com- Incased wallboard has :been madeheretofore prising a machine for themanuiacture of .wall

but the fibrous coverings used have been overboard.

V 20.;- lapped or inserted into the cementitious mate-' Fi 3i sa 0ntak a 0i the D tmeIII -Il II A.

rial in such manner as to materially'weaken the oi-Fig. 2. v V m edge portions of the board or produce undesirable Fi .1 is a section taken along the plane IV--IV elevations inthe board-surface. Inasmuch as 'F i":

wall boardis attached to studding by means of xFig.. s a sectionltakenjalong the Plane V V' nails extending through the edge portions of the of Fig.2. 1 a

board; it is necessary that such edge portions be Fig. 6 is an enlargedseotion taken along the stronger and not weaker than the rest of the p eV VI F s board. Furthermore, it isesser'itial that .the Fig. is-a section taken .along the plane fibrous coverings be tenaciously adherent to each VILi-VI'I of: Fig; 2. p other and to the core as otherwise the coverings Fig; 8' is a.- section taken along the plane 30 are readily torn off during handling and the use- VIII-VIII of Fig.2..

fulnessof the board greatly impaired. U :Fig. 9 isa section taken along the plane IX-IX Generally stated, thisinvention contemplates of Fig.2; j a wall board comprising a cementitious core pro- As shown in-Fig; 1, the' board of this inven- 355 vided with a covering sheet of fibrous material tion comprises 'acementitious core I, a bottom in contactwithone faceof the core and a second fibrous covering 2, and an upper cover sheet of 1 sheet of fibrous material in contact with the other fibrous material. 3. The core I may be composed face of two longitudinal edges of the board, the of any suitableicementitious material or filler. edges of the second sheet extending into theedge Normally, 'gypsumcompositions' are employed as 40 portion of the first sheet or extending. between a core. :Attention is called to the fact that the 40;

laminations at the edge portionsof thefirst sheet, outer edges 4 and 5 of the bottom sheet 2 are such'extending edge being. firmly cemented bebeveled and are cemented into the split edges tween the split edge of thecover sheet. 6 and 1 respectively of the cover sheet 3. The The invention also relates, as stated hereininner surfaces of the splitedges 6 and "I are above, to a particular arrangement of elements coated with an adhesivelnot shown in the drawwhereby a productof the character defined hereings) whichtenaciously binds the beveled edges in above may be readily manufactured, and to a i and 6 with the bifurcated edges of the cover. method whereby the desired structure can be sheet 3. The edge portions l and 5 of the lower readily produced. sheet 2 may be of any desired length so that An object of this inventiomtherefore, is to disthe edges of the cover. sheet 3 may either adjoin close an provide an improved structural matethe-upper corners 'ofthe finishediwall boardv or rial incased in afibrous covering. l I suchedges may be spaced from such corners.

Another object is to disclose and provide a facile Asa result of the construction shown, a full and economical method of making incased wall thickness of cementitious material exists in the board or similar structural material. edge-portions of the wall board, thereby impart slightly narrower than the total width of the board so that the construction described acts as a reinforcing at the edge portions, preventing shattering of the core when nails or other connecting means are driven through or attached to the edges of the boards a The machine diagraimnatically shownin Fig. 2 is eminently suited for the continuous manufacture of the hereinabove described product; al-

though the board can be made by the use of other instrumentalities. As shown in Fig. 2,'-the machine comprises a frame on which a continuous conveyor I0 is mounted. Means fordriving the conveyor are provided although they-are not shown in'the drawings; The bottom sheet 2 of fibrous covering material is supplied from afeed roll l2 and passes through suitable trimming means for trimming the edges .ofthe sheet to the requisite width. The trimming means may include a pair of shafts I3 and I8 carrying discs l5 and 16 respectively; the discs I5 and "overlapping one another in substantially sliding contact. The edges of the discs l5 and 15 are maintained sharp so that a continous cutting action is exerted by the cooperation of said discs upon the fibrous sheet-2; x l

The upper shaft l3 and discs l5 carriedthere by may be driven, although it isnot necessary that-the lower shaft and discs I be driven as the fibrous sheet -2' will' cause said 'discs to jr'og tate, thereby presenting a self-cleaning and new surface to the cutting action. a H

The trimmed sheet may then pass into operating'contaot with scoring means capable of partially cutting into the surface of the sheet forthe'purpose of facilitating subsequent folding of the sheet along predetermined lines. Heretofore difiiculty has been experienced in forming awall board with square and accurate'edges. Attempts have been made to facilitate bending of the sheets in the formation of corners by heading. the same orxformin'g depressions therein, but such methods have not been found satisfactory." If, on the other hand,.a'definite-groove is cut into one face of the fibrous sheet, a suificient amonutofmaterial can thus be: removed so as to insure accurate folding and theformation of axsharp corner; p i

The crimping'means shown in the drawings comprise cutting wheels I! mounted on shaftsdriven by motors It; The motors may be mounts ed upon a suitable framework and be provided with means for adjustably positioning the same with respect to the plane. of the sheet 2. Such means may comprise a threaded bolt 20 having its end journaled in the motor, the bodyof thebolt threadedly engaging a stationary member 2| carried by the support l9. During. the scoring or groove-forming operation, the sheet 2 may pass in contactwith'a-supporting vmember 22 so that the paper is gently pressed against such support during the operation.

During scoring, One surface (preferably the inner surface of the sheet) is partially cut so as to form longitudinally extending grooves spaced at distance substantially equivalent to the width of the finished board. At the same time, additional bevel,

-into theforming portions of the machine.

surface, mounted on shafts driven by motors 24.

Means may be provided for adjustably positioning the grindingwheels with respect to the plane of the sheet, thereby regulating the extent of the The sheet 2 prepared as above described is thencontinuously advanced by the carrier I0 As shown in Fig. 6, folding guides 25 are attached to :the frame of the machine in such position as to raise theedge. portions of the sheet 2 and'fold the same along the grooves 26 made by the scoring discs H. The guides 25 may be adjustably positioned-ontheframe so as to permit adjustment when boards of varying-width are being made; 7 =1 The sheet 2 with edge'portions upturned is then supplied with cementitious material 2Tcontinuously fed to the advancing sheet 2 by means of a suitable feeding mechanism such as the conveyor 28. A cover sheet 3 from the roll 30 is then broughtinto contact with the cementitious material carried by the sheet '2 by meansof the pinch roll 31. This cover sheet 3' may pass through trimmers I5 and l6 and preferably has its edgeportions' split by means of the device generally indicated at '32 (Fig. 2) and shown inxgreater detail in Fig. 7. It is to be understood thatthe cover sheet is preferably made of a laminatedpaper and in the preferred form'of' this invention the edge portions of the cover sheet 3 are split along a lamination fora distance of from about inches to 1 inches. During splitting, the paper is preferably retained between a stationary supporting surface '33 and a yieldable shoe 34 provided'with rcurved ends, such shoe being yieldably pressed .against the paper T by means of a spring35 positioned between said.

The-

shoe and a stationary frame member 36. splitting device itself may assume a number of forms but a self-cleaning type of splitting devicev consistingof :a disc or polygon, has been foundmost effective. 7 a V The disc 3], for example, may be provided with asharp beveled edge portion 38 adapted to enter the paper, the disc lying in a plane parallel to'the plane of the sheet 3. Thedisc 3.1 may be driven as by the motor 39 in a direction opposed to the travel of the paper 3. The base of the motor; 39 may be adjustably positioned on a stationary web 40 so that the depth to which the disc 31 penetrates the paper 3 may be regulated. In a modified form ofthe device, the'shaft on which the disc 31 is" mounted may be provided with a friction clutch on which the tension may be .adjustably regulated and the disc rotated with some slippage .by the. advancing sheet 3 with which it is in'engagement. Astationary knifelil're slitting device may also be used, particularly when the operation of the machine is being initiated.

Thecover sheet prepared as above described is then applied to the surface of the cementitious material" carried by the bottom sheet 2. In addition to the pin'chrollSl, ,the'two sheets may be more firmly compacted around the cementitious material by means of the rolls- 42' and43. l Z

As the two sheets continue their advance, the upper sheet 3 encounters a device for separating the split longitudinal edges of the cover sheet. As shown in Fig. 8, a thin curved and polished metal plate 44 enters the previously formed split in the edge portion of the cover sheet, leaving the upper portion in the manner shown in Fig. 8, the lower portion 6'. of the bifurcated edge remaining in contact with the cementitious material. While the upper edge portion of the cover sheet 3 is in its raised position, an adhesive is supplied to the inner surfaces of such bifurcated edge in any suitable manner as, for example, by means of the atomizer or spraying device 45 supplied with suitable adhesive such as sodium silicate, glue, or the like. Preferably, the inner surfaces of both the upper and lower edge portions of the, sheet 3 are covered'with the adhesive.

- the edge portion 4 within and between the split edge portion of the cover sheet 3.

The continuous sheet thus formed continues to travel until the cementitious material has set,

whereupon the continuous strip may becut into desired lengths and dried in accordance withthe usual practice. I 7

Although a specific form of apparatus and a specific sequence of operations has been described, it is to be understood that the invention is not limited thereto. The formation of the split edge portion can take place while the cover sheet 3 is in contact with cementitious material carried by the bottom sheet 2. Instead of emplaying a spraying device for the adhesive,

brushes or other means may be used. Instead of maintaining the upper portion of the bifurcated edge of the cover sheet3 in raised position by means of a curved metallicguide, such as the element 44, suction can be applied through suitable nozzles to the upper surface of the bifur-.

cated edge so as to raise such edge and maintain the same in raised position during the application of adhesive and insertion of the edge 4' of the bottom sheet 2. 7

These and other changes, modifications and adaptations will occur to those skilled in the art. All such changes coming within the scope of the appended claims. are embraced thereby.

I claim:

l. A wall board comprising a cementitious core,

a sheet of fibrous material in contact with one face of said core, a second sheet of material in contact with the other face and two longitudinal edges of the core, the edges of said second sheet extending into the edge portions of the first sheet.

2. A wall board comprising a cementitious core, a sheet of laminated fibrous material in contact with one faceof said core, and a secondsheet of fibrous material in contact with the. other face and two longitudinal edges of the core, the edges of said second sheet extending between lamina.-

tions at the edge portionslofthefirst sheet: 3. A structuralmaterial in sheet form comprising a cementitious 'core, aisheetiof fibrous laminated material inicontact with: one face of said core, and a second sheet of material in contact with the other face and two longitudinal edges of, the core, the edges of said second sheet extending between laminations and cemented to edge portions of the first sheet.

4. A method of making wall boardcomprising continuously advancing a bottom sheet of fibrous material provided with upturned edge portions, continuously supplyi cementitious material to said bottom sheet, continuously supplying a cover sheet to cover cementitious material carried by said bottom sheet, said cover sheet being provided with edge portions split in a plane substantially parallel to the plane of said sheet, and cementing longitudinal edges of said bottom sheet within the split edges ofsaid cover sheet to form an incased finished wall board.

5. A method of making wall board comprising partially cutting into one surface of a sheet of fibrous material to form longitudinally extending grooves spaced a distance substantially equivalent to the width of the finished board, partially cutting into the surface of said sheet .between said grooves and edges thereof to form groovesspaced from said first named grooves a distance substantially equivalent to the thickness of the finished board, turning up the edge portions of said sheet along said inner grooves, continuously supplying cementitious material tosaid sheet, continuously supplying a cover sheet to cover cementitious material carried by the first named sheet, said cover sheet being provided with edge portions split in a plane substantially parallel to the plane ofsaid sheet, and cementing longi-;

tudinal edges of said first named sheet within the split edges of said cover sheet to form an incased finished wall board.

6. In a method of making wall board, the steps of continuously advancing a bottom sheet of fibrous material provided with. upturned edge portions, continuously supplying a cementitious material to said bottom sheet, continuously splitting the longitudinal edge portions of a cover sheet along a plane substantially parallel to the plane of said cover sheet, covering the cementitiousmaterial carried by the bottom sheet with said cover sheet, and cementing the longitudinal edges of said bottom sheet between the split edges of said cover sheet to form an incased wall board.

7. In a method of making wall board,the steps I of continuously advancing a bottom sheet of fibrous material provided with upturned edge portions, continuously supplyinga cementitious ma-. terial to said bottom sheet, continuously splitting the longitudinal edge portions of a cover sheet along a plane substantially parallel to the plane of said coversheet, covering the cemen titious material carried by the bottom sheet with,

said cover sheet, applying an adhesive to the inner split surfaces of said cover sheet, and inserting the edges of the bottom sheet between the split edges of said cover sheet to form finished wall board.

8. In a method of manufacturing wall board, the steps of continuously advancing a bottom sheet of fibrous material provided with pairs of ah incased longitudina'liy extendinggrooves nearits edges; said pairstof grooves being spaceda. distance sub:v stantially equivalent to the width ofthe finished board, turning up the edgev portions of-said sheet along inner grooves, placing a cementitious -m'a' terial uponi'saidtsheet' :while continuously ad vanoing .thesame, separately continuously advancing-newer sheet of laminated fibrous mas Leriai; splitting the longitudinal edge portions of saidzcover sheet between laminations, and covering' the eementitious :material carried by the bottom sheet with, said cover sheet and cementing the longitudinal edges of the bottom sheet between thesplit edges of .the cover sheet.

' \ALBERTV'H. BRUNNER. 

